Slide 1

DLA Loading Shovel

8. Transmission Electrics

2012.05.10
EMEA Heavy Line Training Team

Slide 2

Transmission Electric System

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Slide 3

Transmission Electric System

- Transmission Circuit (DL420A Example)

LIS Option
Back Up Relay Down Shift Switch
(Joystick)

Speed Sensors
Pilot Cut
off Switch
Parking Brake
Release Solenoid

Speed Sensor

Transmission
Controller
EST37A
Bypass Filter Switch Auto Shift
Transmission Mode Switch
Valve Assembly

Speed Sensors

2 Lever Option

Mono Lever Type Option

Slide 4

Transmission Electric System

- Traveling (Neutral)

When measuring current,

#13 with # 10,56,32,55,9 and 51 are 100 mA
XXXXXX

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Slide 5

Transmission Electric System

- Traveling (Forward 1st)

KV, K1 Clutch engaged

 Y3, Y5 : 500 mA
#13 and#32,#13 and #9 : 9.5V
 Y1, Y2, Y4, Y6 : 100 mA
#13 and other : 1.9V

Slide 6

Transmission Electric System

- Traveling (Reverse 1st)

KR, K1 Clutch engaged

 Y1, Y3 : 500 mA
#13 and#10,#13 and #32 : 9.5V
 Y2, Y4, Y5, Y6 : 100 mA
#13 and other : 1.9V

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Slide 7

Transmission Electric System

- Traveling by F&R switch (2 Lever joystick machine )

Condition of traveling by F&R switch

- DW-3 T/M selector SW : Neutral / 4th gear position and “Auto 2-4” selected

Slide 8

Transmission Electric System

- Kick down (Manual mode : 2nd → 1st )

When selected manual traveling mode and pressed kick down switch, the traveling gear is
shifted down ( 2nd speed gear → 1st speed gear).
And pressed kick down switch again, the traveling gear is shifted up ( 1st speed gear → 2nd
speed gear). It works for 1st and 2nd speed only ( not 3rd, 4th speed)
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Slide 9

Transmission Electric System

- Kick down (Auto mode)

Shift down speed ( press button)

4th → 3rd → 2nd → 1st or 1st → 2nd → 3rd → 4th
4th → 3rd : after 200 ~ 300 engine speed drop

Slide 10

Transmission Electric System

- Transmission cut off

T/M Power cut off function is working

only forward & reverse 1st, 2nd speed
(Not 3rd,4th Speed)
X
X

T/M Cut off switch “On”

with press brake pedal

T/M controller cut forward or reverse

clutch power off.

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Slide 11

Transmission Electric System

- Auto traveling (I)

~
~

~
Shifting machine speed
~ 1st ↔ 2nd ↔ 3rd ↔ 4th
~ Shifting speed depends on
traveling load, machine speed
decided by sensors parameter

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Slide 12

Transmission Electric System

- Auto traveling (II)

~
~

Shift speeding
~
2nd ↔ 3rd ↔ 4th only.
~
When shifting 1st ↔ 2nd ,press
~ down shift switch.
Shifting speed depends on
traveling load, machine speed
decided by sensors parameter

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Slide 13

Transmission Electric System

- Transmission control block valve

Input current (mA) Voltage (VDC)

Resistance
Regulator Output Press (bar)
(Ω)
Neutral Engaged Neutral Engaged

Y1~Y6 100 500 19 1.9 9.5 0.8 ~ 8.3

Condition of Pressure Regulator Operation

1) Parking brake released 2) Transmission Oil Temperature : over – 10 degree C

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Slide 14

Transmission Electric System

- Temperature sensor in T/Mission valve

Condition Function Remark

Open or Short Circuit - Error code display only Resistance : 1000 ~ 1500 Ω
- Travels normally Sensing Temp. for AEB
No Buzzer

↓ -30 degree C (T/M oil) - Parking brake engaged

-30 ~ -10 degree C (T/M oil) - 1st, 2nd speed only

↑ -10 degree C (T/M oil) - Travels normally

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Slide 15

Transmission Electric System

- By pass filter switch

For DL420A

Normal condition Closed filter condition

Resistance (Ω) Closed filter Resistance (Ω)
By pass filter switch Normal
#46 & #17 (= by pass oil) #46 & #17
Open
Closed 500 0
(Error code : BA)
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Slide 16

Transmission Electric System

- Sensors (I)
Central gear
Engine Turbine Inductive transmitter

Engine
inductive
transmitter

Filter switch
Turbine

Out put Central gear Out put

speed sensor speed sensor

DL300A DL420A
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Slide 17

Transmission Electric System

- Sensors (II)

Specification
Sensor Remark
Frequency Resistance(Ω) Gap (mm)

Engine - Output torque Control signal

& 0.5~0.8 - Signal for AEB
Turbine 1050 ± 10%
30Hz~50kHz - Keep the original gap by shim (DL420A
(20℃)
- No need for gap adjustment (DL300A)
Central 0.3 ~ 0.4 - For high speed sensing

- Output Propeller shaft speed

- Travel Speed display signal
Speed 2Hz~5KHz - 1.0~1.3 - LIS system (over 6 km)
- Keep the original gap by shim (DL420A)
- No need gap adjustment(DL300A)
- For high & low speed sensing

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Slide 18

Transmission Electric System

- Sensors (III)

1. Engine & turbine sensor :

Compare engine RPM & turbine RPM Engine
to get working condition or engine
load.

2. Turbine & central sensor :

Compare turbine RPM & central gear Turbine Output
RPM to get clutch slipping condition
or clutch slipping time .

Central

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Slide 19

Transmission Electric System

- LIS System (Switch Position II)

~
~
~

0 I II

Forward - Over 6 km/h : on, Below 4 km/h : off

LIS Sol valve off on
Reverse - Over 4 km/h : on, Below 2 km/h : off

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Slide 20

Transmission Electric System

- Emergency steering (Option)

From fuse box

From starter line

To warning lamp

Condition
Emergency steering Operation
Machine speed
press S/W
Closed 0 km/h EMR motor is not working
Below 4 km/h EMR motor is not working
Open
EMR motor is working
(Brake press. drop) Over 5 km/h
for 60 sec with 1 time.

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Slide 21

Transmission Electric System (ZF General Arrangement)

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Slide 22

Transmission Electric System (ZF General Arrangement)

Position ZF's Description

A1 Electrical Transmission Control Unit EST-37A
A2.1 Gear Selector Lever DW-3
A2.2 Joystick (Customer Supply)
A3 Transmission Hydraulic Control Block
A5 Diagnostic Interface
A6* Display (Customer Supply)
A7 CAN-Interface (Connector)
A9* Speedometer With Frequency Divider (Customer Supply)
B1 Engine Speed Sensor
B2 Turbine Speed Sensor
B3 Internal Speed Sensor
B4 Output Speed Sensor
B15 After Converter Temperature Sensor
B17* Brake Pedal Sensor (Customer Supply)
F1 Fuse 7.5A
F2 Fuse 7.5A
H7 Warning Light: Joystick Selected
K1 Starter Interlock Relay
K2 Back Up Alarm Relay
K5 Ground Speed Controlled Relay (LIS)
S6 Down Shift Button
S8 Preselection Switch For Lock-Up Clutch Off (Option)
S10 Filter Restriction Switch
S28.1 Preselection Switch For Ergotraction Auto Mode (DHL)
S28.2 Preselection Switch For Ergotraction Manual Mode (DHL)
S31 Parking Brake Feedback Switch
S46 Selector Switch Joystick
Y7 Lock-Up Clutch Proportional Valve (Option)
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Y9 Differential Lock Solenoid Valve
Slide 23

End of Document

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